Final Project Monu

ELECTRONICS AND COMMUNICATION
A
TRAINING REPORT
ON
“PRODUCTION OF ENERGY METER”
TAKEN AT
( A KAILASH GROUP COMPANY )
From: 24th may to 24th june
GUIDED BY :- SUBMITTED BY :-
Dhram pal Singh Mahendra Agarwal

B.E. IIIrd Year
Electronics & Communication
GENUS Overseas Private Limited Engineering
JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY
JNIT
DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING
JAGAN NATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY
JAIPUR (RAJASTHAN)
CERTIFICATE
This is to certify that the report entitled

“Production of Energy Meter” is submitted by
Neelam Jangid, a student of B.E. in Electronics and
Communication Engineering, in partial fulfillment for
award of the degree of Bachelor of Engineering in JNIT,
Jaipur during session 2008-2009.
This report has been found satisfactory by me and is
approved for submission.
Date: Mr. Deepak Chaturvedi

Place: Jaipur H. O. D.
E. C. E. Deptt.
JNIT, Jaipur
ACKNOWLEDGEMENT
I feel highly privileged to express my sincere thanks and deepest sense of gratitude to my
guides Mr.Dharam pal Singh of Genus, who has spared their precious time & guided me to
complete this project. I sincerely acknowledge them for extending their valuable guidance,
support for literature, critical review of report & above all the moral support they have provided
mw at all stages of this work.
I express my deepest sense of gratitude towards Mr. Deepak Chaturvedi, HOD

Department of Electronics and Communication, JNIT, Jaipur. I also express my deepest sense
of gratitude towards Mr. Deepak Agrawal, PTS, JNIT, Jaipur for clearing my doubts at any time
of need and valuable inspiration during the seminar work.
My thanks are extended to all staff members and persons who directly or indirectly helped
me in achieving my goals.
I could not have completed this work without the guidance of my parents. They deserve
more credit than I can give for instilling in me a good work ethic and a desire to always learn
more.
My thanks are extended to all friends who gave me nice company and kept my spirit high
throughout this work.
Mahendra Agarwal

PREFACE
This training report submitted by me is written on the basis of
the practical gained during my training period.
I had completed this report. It’s a great pleaser & satisfaction to
develop energy meter. I lean to tackle different problems that come
while developing any report.
We have tried to include all those that are required for a good
report. But, besides best effect, it may have few shortcomings.
Mahendra Agarwal

CONTENTS
TOPICS PAGES
1. INTRODUCTION……………………………………………………………………….1 - 3
1.1. APPLICABLE STANDARDS
1.2. QUALITY SYSTEM
1.2.1. QUALITY ASSURANCE
1.2.2. IS0 9001 CERTIFICATE OF REGISTRATION
1.2.3. SCOPE OF THIS CERTIFICATE
1.2.4. ISI MARK
2. ENERGY METER.................................................................................................3 -10
2.1. CONSTRUCTION
2.2. PRINCIPLE OF OPERATION
2.3. DISPLAY PARAMETERS
3. 1-PHASE ENERGY METER PRODUCTION PROCESS…………………………10 - 14
3.1. PROCESS
3.2. PROCESS FLOW FOR FINISHED GOOD & PACKING
4. 3-PHASE WHOLE CURRENT METER……………………………………………..14 - 19

4.1. PROCESS
4.2. FLOW CHART (F G LINE)
5. 3-PHASE WHOLE CURRENT METER……………………………………………..19 - 23
5.1. SALIENT FEATURES
5.1.1. MEASURED PARAMETERS
5.1.2. SELF- DIAGNOSTIC FEATURE
5.1.3. LOAD SURVEY
5.1.4. MAXIMUM DEMAND
5.1.5. COMMUNICATION
5.1.6. LEDS
5.2. DISPLAY DATA
5.3. ANTI-TAMPER FEATURES
5.4. INSTALLATION
5.5. SPECIFICATION SHEET
5.5.1. RATING
5.5.2. TAMPER DETAILS
6. ANNEXURE…………………………………………………………………………….23 - 28
6.1. PUSH BUTTON MODE
6.2. AUTO MODE
6.3. TAMPER THRESHOLDS (G336)
6.3.1. TAMPER PERSISTENCE TIME FOR
OCCURANCE/RESTORATION
6.3.2. TAMPER LOGS
7. CONCLUSION………………………………………………………………………….29 - 29
8. BIBLIOGRAPHY……………………………………………………………………….30 - 30
LIST OF FIGURES
FIG. NO. FIG. NAME PAGE
(i) 3-PHASE STATIC WATT HOUR METER 9
( ii ) 3-PHASE WHOLE CURRENT METER 19
( iii ) CONNECTION DIAGRAM OF 3-PHASE 22
WHOLE CURRENT METER
1. INTRODUCTION
GENUS was established in 1995 in the historic pink city of India, jaipur. We are a leading
manufacturer of GENUS OVERSEAS ELECTRONICS LTD.: - An ISO-9001 company is a public
limited concern with an investment of US$ 7 million. The company has been promoted by K.C.C.
group of industries having interest in diversified fields, with a group turnover of more than US$
65 millionthick film hybrid microcircuits in India. We have three SMT lines dedicated to
manufacturing of PCB assemblies. The annual plant capacities of hybrid microcircuits and PCB
assemblies are 4.50 million square inches respectively. The plant produces more than 2.4
million single phase and three phase electronics electricity meters annually.

GENUS has the most modern plant with class 10,000 and 100,000 clean room work areas. The
advanced design software, latest manufacturing equipment and automatic testing systems
ensure highest quality products at competitive prices.
As a result, many complex HMCs requiring high component count in a very limited area, while
meeting increased reliability and robustness requirement for different applications including
defence have been developed. GENUS is now supplying hybrids to telecom, Industrial, Defence,
Consumer, Automotive, and informatics, power sectors and for metering products too.
GENUS is also engaged in electronic manufacturing services, which besides contract
manufacturing of SMT/Through-hole PCB assemblies includes supply of enclosures/ casings
and accessories, wherever applicable. The workmanship of PCB assemblies has been well
received by customers both in India and abroad.
The strength of GENUS lies in its strong design and development team, instrumental in
development of low end ASIC based electricity meters to high end programmable multi-
functional intelligent single phase & three phase meters with in-built advanced security and anti-
tamper features. Expertise in embedded software ensures that our products are customized as
per the specific requirement.
GENUS has a fully equipped modern tool room with the latest CAD/CAM software and CNC
machines. Qualified teams of product designers rich experience in die and mould design, have
enhanced our capabilities of offering customized products in HMC modules, assembled PCBs.
Electronic energy meter and other metering solutions. GENUS is continuously updating its
product portfolio with new products and solution. Recent developments are digital taximeter, pre-
payment meter, AMR enabled meters and several turnkey projects in related areas.
GENUS has been accredited with ISO-9001, IECQ, EMC, ISI and C-DOT Certifications. The
experience and exposure to international level of excellence has equipped GENUS to face and
adapt to the challenges and opportunities emerging in the world today.

1.1 APPLICABLE STANDARDS
For design manufacturing and testing of this meter following national and international standards
have been referred to;
(a) IEC 61036: (2000-09) Alternating current static watt-hour meters for active energy. (Class
1 and 2)
(b) IEC 61010-1: Safety requirement for electrical equipment for measurement, control and
laboratory use.
(c) IS 13779:1999 a.c. static watt hour meters, class 1 and class 2 – specification
(d) CBIP 88 Revised: a.c. static watt hour meters
1.2 QUALITY SYSTEM

1.2.1 Quality Assurance
The Quality Policy at GENUS emphasize on offering the best quality products and
services conforming to international quality standard, and is accomplished by making
every individual responsible for quality.
In-house reliability tests are conducted on THERMAL SHOCK, HUMIDITY & BURN – IN
chambers to ensure satisfactory performance and quality over the entire product range.
1.2.2 ISO 9001 Certificate of Registration:

STQC Certification services, under ministry of information technology, government of
India after verifying the quality system being followed, has certified that GENUS has
established and is maintaining a quality system fulfilling the requirements of ISO 9001:
2000
1.2.3 The scope of this certificate covers:
● Design manufacturing & supply of thick film hybrid microcircuits.

● Design, contract manufacturing & supply of PCB (SMT and through hole assemblies.
● Design, manufacturing, supply & servicing of static energy meters.
1.2.4 ISI Mark:

Bureau of Indian standards (BIS), a certification body established under the bureau of
Indian standards act 1986 has given license to use standard mark of the bureau on
GENUS make AC static watt-hour meters of following specifications as per IS 13779:
1999
AC STATIC WATTHOUR METERS, SINGLE PHASE, WHOLE CURRENT 2 WIRE 240V,
50Hz; different current ratings & class.
AC STATIC WATTHOUR METERS, THREE PHASE, WHOLE CURRENT, 4 WIRE,
3X240V, 50Hz; different current ratings & class.
Presence of certification mark known as standard mark (ISI) is an assurance of conformity to the
relevant specification.
2. ENERGY METER
•What is an Energy Meter?

•Energy meter is a device to measure the consumption of energy by the consumer.
•How accuracy of the meter is defined?
•As per IS 137779/ IEC61036/ ID13010 accuracy of the meter is defined by comparing the
difference of energy consumption recorded by “Meter under test” and of “Reference Meter”
with the energy consumption recorded by a reference meter.
Accuracy(%) = (EMUT - ERef) x 100

•The accuracy of both Mechanical and Electronic meter is defined by above equation.
•Which is more accurate- mechanical meter or electronic meter?
•Electronic meters are more accurate than mechanical meter. The best mechanical meter can
have an accuracy of 0.5% whereas electronic meter are available up to accuracy of 0.005%.
Almost all meters for industrial, grid, transformers and for bulk consumers are electronic meter.
•How the meters are classified and what are the relevant technologies?
•Meters are classified as following: -
•a. Household single-phase meter - Mechanical/ Electronic meter
•b. Household three-phase meter -
Mechanical/ Electronic meter
•c. Commercial Meter - Electronic meter
•d. Industrial Meter - Electronic meter
•e. HT Meter - Electronic meter
•f. Grid Meter - Electronic meter
•g. Reference Meter - Electronic meter
•What is the meaning of fast meter?
•In general if a meter is found recording more energy in comparison to other meter; it is called as
fast meter. This comparison is quite misleading. As defined earlier a meter with positive
accuracy error only should be called as fast meter
•Why electronic meter are considered as fast meter?
•If two meters are accurate, than under the recommended reference conditions they will record
same irrespective of the technology. However, due to following parameters it is observed that
mechanical meter record less consumption: -
•a. High Starting current
•b. Narrow Current range
•c. Installation method
•Aging process
•What are the various ratings of meter and how they are defined?
•Various ratings of meter are as following: -
Ratings Range
•
2.5-5A (Mechanical)25mA-5Amp
•5A-10A (Mechanical) 50mA-10Amp
•5A-20A (Mechanical) 50mA-20A
•10-40A (Mechanical) 100mA-40A
•5. 10-60A (Electronic) 20mA-60A
•* Typical starting current of Mechanical meter is 1% Ib (If old) and of BSES meter is 0.2%.
•What is the effect of parameter “starting current” on energy consumption?
•Since mechanical meter required an initial torque to start so mechanical meter do not record
low consumption. Thus, the load with low consumption remains unrecorded. With electronic
meter even low load can be recorded and thus, consumer feels that electronic meters are fast.
•What is the effect of “current range” parameter on energy consumption?
•Current range of meter is the working range over which the meter records the energy correctly.
In general, the current range of mechanical meter is much narrow than electronic meter. If the
load of the consumer is beyond the range of meter than the excess load remain unrecorded.
Since, electronic meter has a wide current range so chances of consumer drawing the load
beyond the permissible range are negligible and thus it records the actual power consumption.
It is widely observed that consumers having decades old mechanical meters, presently having
connected load far more than sanctioned load (and thus far beyond the current range of meter)
are thus paying very low electricity charges as meter is not able to record the correct
consumption. This is inspite of the fact that the meters are accurate.
•What is the effect of installation parameter on energy recording?

•In mechanical meter torque generated due to power consumption rotate the rotatory system,
which is balanced on accurate but sensitive bearings. In case the meter is installed with a tilt
either sideway or front/ back way than it affects the energy recording and which will be always
lower than actual. This is one of the biggest drawbacks of mechanical meter. With electronic
meter, since there is no moving part so the accuracy of same is independent of installation.
•What is the effect of aging of energy consumption recording?
•Since the mechanical meters have moving parts, so with use these have the tendency of wear
and tear resulting in low energy consumption. Same is not applicable for electronic meter as it is
a static device.

•Meters accuracy are defined at reference conditions. However, in field voltage,

Frequency and Temperature are different. What is the effect of the same?
•The permissible effect of field voltage, frequency and temperature on accuracy is defined in IS/
CBIP/ IEC standards. The energy meter in India, in general follows these standards. Although,
there is an influence of the above parameters but the same is not highly significant.
•Can the accuracy of meter be altered in field?

•All service companies prefer to buy those meters in which the accuracy of the meters cannot be
altered in the field. If the meter accuracy can be altered in the field by the service company than
same can be altered by the consumer also. Service companies cannot take risk with such type
of meters and thus only buy the meters, which are welded and cannot be altered in the field.
•What are the responsibilities of ISI license holder?
•After evaluating the product and the manufacturing capabilities, the Bureau of Indian Standard
(BIS) issue the ISI license to the manufacturer. Meter manufacturer has to ensure all meters
strictly follow the relevant IS and also test records of the same are maintained. The mis-concept
that the service company can ask manufacturer to make meters with very high positive error
(fast meter) is not possible as if it is found so, the ISI license of the manufacturer can be
withdrawn by BIS.
•What is the Maximum Demand Indicator (MDI)? What is its significance for consumer?
•Maximum Demand Indicator is an indication about the maximum load used by the consumer for
the duration of half-an-hour in the given period. This parameter is significant both for consumer
and the service company to decide the sanctioned load and also to plan the network capacity.
•What is the meaning of down loading of parameter?
•Various parameters measured and recorded by the instrument are finally downloaded for billing/
monitoring purpose. The downloading of parameter means transferring the parameters from
meter to the records of the service company. Downloading can be manual i.e. by reading the
LCD display recording on a notebook or using some gadgets.
•What is the meaning of MRI reading?

•The gadget used for downloading of is called Meter Reading Instrument (MRI). The biggest
advantage of MRI reading is that it avoids human error in recording/ transfer of data.
•What is AMR system?

•Downloading of the parameters using electronic gadgets, which are attached to the meter
without manual intervention, is called Automatic Meter Reading (AMR) system. The gadget
attached to the meter downloads the parameter and than automatically communicate to the
computer of the service company.
•What is the E/L LED? When it glows?
•EL LED is an indication for unequal current flowing through phase and neutral. This mis-match
can be either due to shortening of neural to earth/ leakage of current to earth/ the wire of two
premises are touching each other.
•What action consumer should take if EL- LED glows?
•In case the EL.- LED found glowing, the consumer should get his wiring checked for the above-
mentioned defects.
•What is the significance of REV LED?
•REV LED indicates the reverse flow of energy from consumer to the grid.
•What action consumer should take if REV LED glows?
•In case REV LED is glowing than the consumer should ensure that generator/ inverter shall be
totally isolated with the grid. Ever after that REV LED is found ON the consumer should call
the service company for the check.
Kindly note:- Glow of REV LED does not affect the accuracy of energy meters. Some time “REV”
LED glows at “no load” condition and shall be ignored.
•What is the role of “N cut” and what action consumer should take?
•LED “N cut” (which is provided in few meters) indicates about loosening of wire at the meter
end. In case consumer finds such LED glowing he should call the service company for
retightening of all the wires in the meter to ensure proper supply to meter.

2.1
CONSTRUCTION
The line diagram of the three phase electronics meters is as shown in appendix –01 and the
description of various parts is as follows:
a) Base & top cover are made of engineering plastic and meets the requirement
of IS: 13779. its manufacturing drawing is shown on appendix-01.
b) Current transformer (CT): - current transformer, 5000 turns are used. The
CT is placed in a PVC casing. An insulating cup separates the winding from PVC casing
and connecting wires are soldered at connecting points. The PVC casing is then filled
with a good quality epoxy (CIBA or Dr.Beck) the winding are used is 40 SWG super
enameled copper and connecting wires are ISI marked good quality 7 strands. 36 SWG
wires. Its manufacturing drawing is showing in appendix 01.
c) Counter: - the counter used is (6+1) liquid crystal display (LCD) type counter
of good quality & its manufacturing drawing is showing in appendix 01.
d) Terminal cover: - transparent terminal cover is made of engineering plastic
and its manufacturing drawing is shown in appendix-01.
e) Name plate: - the nameplate is fixed inside the meter on the topside of the
front face and is visible through the top cover. The arrangement is such that no
manipulation on the nameplate is possible without opening the top cover. The
nameplate provides information on the following.
f) Terminal Block: - the terminal block is used for making the external
connection between the incoming single-phase supply along with the neutral to the
single-phase load with outgoing neutral terminal. The two terminal screws per terminal
can be used to tighten the wires fully to avoid any over heating. Brass terminal are
housed in the terminal block for the above purpose. The terminal block has been
robustly designed for carrying 100% of Imax currents.
g) Sealing: - top cover and base can be sealed with the help of two sealing
screw provided. Terminal cover can be sealed with the help of one sealing screw.
h) Mounting: - the meter can be mounted with the help of two mounting screw,
one at top and two at the bottom within the terminal block.
2.2 Principle of operation

This document covers operation of three phase four wire. 3 x (10-100) A. static watt-hour meter,
class 1.0 accuracy of GENUS makes. Used for measurement of energy (kilowatt-hour)
consumption. The operation of the meter is simple but still GENUS recommends thorough
reading of the document for proper use of the meter. Also by going through the document, all the
features of the meter could be put into full use. The GENUS WHOLE CURRENT kWh meter is
intended for three phases. Four-wire system of rating 3x240v, 3x(10-100) A, 50hz.
GENUS three phase, four wire WHOLE CURRENT kwh meter is powerful data acquisition and
digital signal processor (DADSP) and micro-controller based electronic energy meter, meeting
all three-phase power and energy meter measurement requirements. The meter consists of a
fast data acquisition and digital signal processor and a micro-controller with flash memory to
store the metering program and data. A resistor divider network scale down the three phase
voltages measured by the meter. Meter measures total energy (kwh) i.e., fundamental plus
harmonics. Line currents are sensed through current transformers.
A 6-channel digital signal processor bit A-D converter digitized and current signals and sends
the data to the DADSP. The DADSP stores the acquired digitized current and voltage and
signals in its internal data memory for computation of various parameters. The micro-controller
manages all the peripherals including the non volatile memory, LCD display. In addition to
peripheral management, the micro-controller performs the complete data management also.
Meter is factory calibrated, therefore no external calibration is required for this meter
Block Diagram (i)

+10V -5V
R-Phase CT
Y-Phase CT Crystal
LCD
B-Phase CT Energy register
Digital signal processor

R-Phase
Timing & control unit
Y-Phase
B-Phase
Neutral Micro Controller EPROM
+5V
-5V
-2.5V Crystal
O/P, CAL Phase
2.3 Display parameters

The GENUS –WH meter is capable of measuring and displaying following energy parameters.
Cumulative active energy : KWh
GENUS make Three Phase, Four Wire, Whole Current four-quadrant electricity meter is based
on a powerful multiprocessor (metrology ASIC & control processor) platform. A dedicated ASIC
sample the voltage and current waveform of each phase in parallel using six separate.∑∆ (sigma
delta) analog to digital converters. This ensures true RMS calculation up to 30 th harmonic of the
power line frequency. The sampling Rate is 320K samples per second.
The control processor simultaneously carries out the real time calculation of parameters,
manages the memory, display, RTC and the serial communication.
Resistor divider networks are used to sense three Phase voltages & DC tolerant Current
transformers are used to sense Load currents. ASIC does the computation of power based on
input voltage & current signals & transfer digital data to control processor.
Two communication ports are provided in the meter for data downloading.
a. An optical port for transfer of meter data to PC / CMRI.
b. An Isolated wired RS232 port (RJ11) for remote meter reading.

2. 1-Phase Energy Meter Production Process
3.1 PROCESS
(Specific project -: Base and PCB )
Put NL and PL terminal in T. Block
Tight screw M4X8 of lower side of NL & PL

terminals
Put PS & NS terminals in Jig
Put glue stick between Ph & Nu primary in Power

CT
Tight Shunt, Ph wire, MOV & 10nF in PS with

M4X6 screw
Tight Nu primary, Nu Wire, MOV & 10nF in NS with

M4x6 screw
Place the PS and NS terminals assy in Base
Tight M4X8 screws in PS & NS terminals
Put Metal CT in Nu primary & tight in meter base

with 4x9.5 ST screw

Connect Nu primary on NL and shunt on PL with
M4X6 screws
Tights remaining M4X8 screws in PL & NL

terminals
Put 4mm sleeve on CT wires & Shunt wires
Put PVC sheet on base with double sided tape
Insert PCB in base slot
Solder Ph, CT and Shunt Wire on PCB
Meter LT on Jig
1) Put Meter on CT lead of Jig
2) Tight Meter on Jig with help of handle
3) Phase crocodile on PS Terminal & Nu crocodile
on n1 on PCB
4) Ph Nu on & load give to Meter in normal
condition, check Volt in Display & Cal LED start
blink
5) Give earth load to Meter with help of earth
switch of Jig, check Earth in Display, Volt in
Display & Cal blink
6) Earth switch of Jig put in normal
7) Give reverse load to Meter with help of reverse
switch of Jig, check Rev in Display, Volt in Display
& Cal LED blink
8) Give earth & reverse combined load to Meter
with help of earth & reverse switch of Jig, check
Volt in Display, Rev in Display, Earth in Display &
Cal LED blink
If Meter is passed in LT tests, then Meter keep in

the Meter Rack for Meter testing or if it is failed,
then send to rework for rectification

3.2 Process flow for Finished good and Packing
Take tested Meter for FG
Remove Bergstick from N1 (PCB)
Solder Nu wire N1 on PCB with proper wire routing
Meter LT on Jig
3) Phase crocodile on PS Terminal & Nu crocodile
on NS Terminal
4) Ph Nu on & load give to Meter in normal
condition, check Volt in Display & Cal LED start
blink
5) Give earth load to Meter with help of earth
switch of Jig, check Earth in Display, Volt in
Display & Cal blink
6) Earth switch of Jig put in normal
switch of Jig, check Rev in Display, Volt in Display
& Cal LED blink
8) Give earth & reverse combined load to Meter
with help of earth & reverse switch of Jig, check
Volt in Display, Rev in Display, Earth in Display &
Cal LED blink
Check error on Jig
Put the Name plate on Meter

Put Button in Top Cover
Meter Top Cover fixing
Ultrasonic welding
Socking
Note initial reading before socking & final
reading after socking of Meter & Ref Meter
Check display parameter, digit cut, display
blinking
FG file run through optical port by computer
Check error on Jig
Check display parameter
Tight Screw for fixing Meter Top & Base
Meter Sealing

Tight Ter Cover Screw on Ter Block & Put Ter

.
cover in base on LHS
QA check point
Meter mount in Enclosure with Ultrasonic riveting
Mount communication cable from Meter to

Enclosure
Check communication thru communication Cable
Put Accessories in Enclosure
Put polythene with Meter, TC & accessories into

Corrugated Meter Box
Put Corrugated Meter Box in Corrugated Master

Box
General Points to be taken care during Production:

1. All Measuring Instruments and Jigs should be duly calibrated with valid calibration
certificate.
2. Screwdrivers, Wire strippers, Tweezers, Nose Pliers etc. should be in good working
condition.
3. Tip of the Solder Iron should be fine.
4. Lighting arrangement should be adequate.

5. Air pressure for Pneumatic Tools should be maintained.
6. Proper Earthing should be at all points.
7. Antistatic arrangement should be proper at all relevant workstations.
8. Proper House keeping.
4. 3-Phase Whole Current Meters

4.1 PROCESS
(Base-PCB Line Specific Project: G336)
Put CT Terminals in TB
Tight CT Terminal Screw on Terminals
Mount Base Shielding in Meter Base
Mount Hanger Plate in Meter Base
Mount Insulation Sheet in Meter Base
Mount Base plate in Meter Base
Put TB in Meter Base
Tight I-Patti for TB mounting at both ends

CT mount & tight on Terminals
Mount Line filter
Tight below screw of TB for LT & QA Inspection
Solder Phase wire (RYBN) on SMPS
Solder R-CT, Y-CT, B-CT wire on Main PCB
Mount PCB Assy on Meter Base
Tight Nu wire on Nu CT Terminal & QA Inspection
Meter LT on Jig
3) Phase crocodile (RYB) on PT wire (RYB)
4) Switch on R Ph & Nu in normal condition check
R Ph LED glow & Cal LED starts blinking
5) Give reverse load with help of reverse switch of
Jig, check R Ph LED glow, tamper LED glow & Cal
LED starts blinking
6) Repeat steps 4 & 5 for Y & B Ph also
7) Switch on RYBN in normal condition check RYB
Ph LED glow & Cal LED starts blinking
8) Give reverse load with help of reverse switch of
Jig, check RYB Ph LED glow, tamper LED glow &
LED starts blinking
If Meter is passed in LT tests, then keep the Meter

in the specified Rack for Testing. If failed, then
send to rework for rectification
4.2 FLOW CHART (FG Line )
Take tested Meter for FG
Tight Ph wire (RYB) on CT Terminal
Remove LCD Tape
QA Inspection
Meter LT on Jig
3) Switch on R Ph & Nu in normal condition check
R Ph LED glow & Cal LED starts blinking
switch of Jig, check R Ph LED glow, tamper LED
glow & Cal LED starts blinking
5) Repeat steps 4 & 5 for Y & B Ph also
6) Switch on RYBN in normal condition check RYB
Ph LED glow & Cal LED starts blinking
switch of Jig, check RYB Ph LED glow, tamper
LED glow & Cal LED starts blinking
FG file run optical port by computer
Name plate fixing on Meter

Put Top cover on Meter Base
Soaking
Note initial reading before socking & final reading
after sacking of Meter & Ref Meter
Check display parameter, digit cut, display blinking
QA Inspection
Check error on Jig
Tight Sealing Screw for fixing Meter Top & Base
Terminal Cover fixing on Meter with help of Hinge

Pin
Mounting Meter in Enclosure Base with use of

bottom Pillar of Enclosure
Terminal Cover fixing with help Terminal Screw
Communication Cable fixing on Meter Top (with

use of Pillar) to Enclosure Base
Check display parameters & QA Inspection

Put Enclosure Top on Enclosure Base
Put Enclosure Assy (with Meter & Accessories) into

polythene Bag
Put polythene with Meter into Corrugated Meter

Box
Put Corrugated Meter Box into Master Box
General Points to be taken care during Production:

9. All Measuring Instruments and Jigs should be duly calibrated with valid calibration
certificate.
10. Screwdrivers, Wire strippers, Tweezers, Nose Pliers etc. should be in good working
condition.
11. Tip of the Solder Iron should be fine.
12. Lighting arrangement should be adequate.
13. Air pressure for Pneumatic Tools should be maintained.
14. Proper Earthing should be at all points.
15. Antistatic arrangement should be proper at all relevant workstations.
16. Proper House keeping.

5.1SALI
5. 3-Phase Whole Current Meters
ENT
Fig (ii)
FEATURES:
5.1.1 Measured Parameters: Meter measures following parameters: -

a) Active energy
b) Reactive Energy (lag)
c) Reactive Energy (lead)
d) R-Phase Irms
e) Y-phase Irms
f) B-phase Irms
g) R-N Vrms
h) Y-N Vrms
i) B-N Vrms
j) Frequency
5.1.2 Self-Diagnostic Feature

Meter has inbuilt capability to perform self-diagnostic & display error if any for following: -
a. Time and date on meter display

b. All display segments on meter display
c. Real time clock status in meter reading print outs at BCS end
d. Non-volatile memory (NVM) status in meter reading print outs at BCS end.
e. Battery Status
5.1.3 Load Survey:

Meter record following parameters on FIFO basis with Date & Time stamp: -
a. Active Power/Energy (kW / kWh)
b. Apparent Power/ Energy (kVA/ kVAh)
c. Reactive Power/ Energy(kvar/ kvarh) (lag and lead)
d. Power Factor
e. Phase voltages (R, Y, B)
f. Phase currents (R, Y, B)
5.1.4 Maximum demand:

The meter continuously monitors and calculates the average demand in kW & kVA during the
integration period set and maximum out of these shall be stored.
MD is calculated on real time basis ½ hr.
5.1.5 Communication:
The meter has serial communication port supporting all PC activities.
An optical communication port is installed on front panel for serial communication. The Baud
rate for optical communication is 9600 bps. One more optional RS232 port is provided in
terminal block for AMR communication.
5.1.6 LEDs
The meter has the provision for 6 LEDs. There functions (from left to right) are:
 Active Energy Calibration LED: The LED acts as the metrological output for the Active
energy Register.
 R phase LED: The LED acts as an indication to the availability of R Phase Voltage.
 Y phase LED: The LED acts as an indication to the availability of Y Phase Voltage.
 B phase LED: The LED acts as an indication to the availability of B Phase Voltage.
 Tamper LED: The LED indicates the presence of one or more tampers/ Anomalies.
 Reactive/ Apparent Energy Calibration LED: The LED acts as the metrological output
proportional to either Apparent or Reactive Energy ( Configurable & Optional)
5.2 DISPLAY DATA:

Please refer to the attached annexure for the display details of this model.
5.3 ANTI-TAMPER FEATURES:

Below is an exhaustive list of anti tamper detection / evidence features.
 Current Polarity Reversal- The meter is capable of detecting and recording
occurrences and restoration of CT polarity reversal of one or more phases. When any
current polarity is reversed, it is treated as current polarity reversal.
 CT open/short or bypass detection: The meter has the capability to detect opening or
bypassing of one or two current circuits connected to the meter along with date and time.

 External Magnetic Tamper detection: The meter has the capability of detecting and
recording if an abnormal external magnetic field is induced so as to affect the functioning
if the meter..
 Meter will indicate tamper when phase voltage or any other spurious signal is fed to
neutral or if the neutral is disconnected.
Meter will log date and time of tamper occurrence & restoration along with snapshots of
various parameters such as kWh, kVAh, Net PF, phase voltages and phase current.
5.4 INSTALLATION:
Connection diagram (iii) : -
After installation, the following things must be verified:-
 The tamper led must not be glowing. If it does-

 Check for the source of anomaly on the display of the meter.
 In case of Current reverse the respective phase LED will blink,
Check the polarity of the connections.
 If phase sequence error, check the connections for phase sequence anomalies.
 Check if the Phase LEDs are glowing and not blinking. If not, check if the connections
are proper.

5.5 Specification Sheet:

5.5.1 Rating:
Voltage Rating: 3x 240/ 415 volts
Current Rating: 10-60 A
5.5.2 Tamper Details:
Missing Potential
Phase Polarity Reversal
Ct Open/ Bypass
Magnetic Tamper Detection
Neutral Disturbance
Split Phase
Neutral open
Top Cover Open
Current Reverse
Voltage Unbalance
Current Unbalance
Over Voltage
Over Current
THD
6. ANNEXURE
6.1 Push Button Mode
ALL SEGMENT DISPLAY
LCD check


ερρ Ρ Τ Χ ΦΑ Ι Λ
RTC check
δο τ ε δ:µδµ:ψ ψ
1 Real Date
τΙν ε η:µηµ :σ σ
2 Real Time
Σρµ ο 0 0 0 0 0 0
3 Serial No.
04 ρδχ τ 0 0
4 Reading count
05 ρ σ τ
5 0 0 MD reset count
MD

06 0
000 0 0 .0
6 Cumulative kvarh - Lag
CUM
kVAr h
07 0
000 0 0 .0
7 Cumulative kvarh - Lead
CUM
kVAr h
08 0
0 0 .0 0 0
8 Cumulative MD kW
CUM MD
kW
09
9 0 .0 0 0 Instantaneous Power Factor
PF
ρ
υοΛΤ
10 0 0 0 .0 Instantaneous R Phase Voltage
Instantaneous Y Phase Voltage

11
υοΛΤ ψ
0 0 0 .0
υοΛΤ β 0 0
12
0 .0 Instantaneous B Phase Voltage
Χ υ ρ ρρ
13 0 .0 0 0 Instantaneous R Phase Current
Χυ ρ ρ ψ
14 0 .0 0 0 Instantaneous Y Phase Current
Χυ ρ ρ β
15 0 .0 0 0 Instantaneous B Phase Current
16 Π 0 0 0 0
16
0 Active Load Watts
W
Tamper status
17
17 νο τ π
ρ
18 τΧ
18 0 0 0 Cumulative Tamper counts
CUM
19 τΧ βψπσ
19 0 0 0 Cumulative Bypass Tamper counts
CUM
2 0 τ ΧΧ τρ
Cumulative CT reverse Tamper
20 0 0 0 counts
CUM
21 τΧ ΧτΟ 0 0
21 0 Cumulative CT open Tamper counts
CUM
22 τΧ µο γ τ 0 0
22 0 Cumulative Magnet Tamper counts
CUM
2 3 τ Χσ πη Cumulative Split phase Tamper
23 0 0 0 counts
CUM

24
24 000 0 0 0 .0 Cumulative kWh
CUM
kWh

ερρ
ΡΤΧΦΑ Ι Λ
RTC check
01
0 0 0 0 0 0
Cumulative kWh
CUM
kWh
02β 1
000 0 0 0 .0 Billing kWh
BP
kWh
03β 1
000 0 0 0 .0 Billing kVAh
BP KVA
h
04β 1
0 0 00
. 0 Billing MD kW
BP MD kW
05β 1 ΑΥ Γ
0 .0 0 0 Billing Average power factor
BP PF
06
0 0 .0 0 0 MD kW
6.2 Auto Mode:

6.3 Tamper thresholds (G336)

(3 Ph 4W 3x240 V, 50 Hz, Class 1)
S.
Tamper Type Store Thresholds Restore Thresholds
No.
Current direction –ve Current direction +ve

1 Current Net PF > 0.2 Net PF > 0.2
Reversal Ix > 10% Ib Ix > 10% Ib
Vx > 40 % Vref Vx > 40 % Vref
Any one voltage < 10 % All three voltages>

2 Split Phase Vref 75 % Vref
Other two voltages > 75 %
Vref
Two Phases currents > 10
% Ib
Difference between two
currents < 500 mA
3 Magnet Meter Under Magnetic field Meter Not Under

Interference Magnetic field
4 CT Open Vx > 40 % Vref Vx > 40 % Vref

Ix < 0.1 % Ibasic Ix > 0.1 % Ibasic
Difference between two
currents> 30 % Ibasic
5 CT Bypass Iavg > 10% Ibasic Ibypass < 20 %

Ibypass > 30 % Ibasic Ibasic
6.3.1 Tamper Persistence time for Occurrence / Restoration:

Programmable, by default 5 minutes(For Occurence) and 2 Minutes(Restoration) is
programmed. For magnetic tamper, persistence time is 15 sec.
6.3.2 Tamper Logs:
Each Block can store 160 events, i.e. 80 store and 80 restore.
Meter will log Date & Time of tamper occurrence & restoration with snapshots of kWh, kVah,
Phase Wise PF, Voltages (R, Y,B) & Current (R,Y,B)
Vref = 240 Volts, Imax = 60 A, Ibasic = 10 Amp

7. CONCLUSION
At the last I conclude that my training under such an organization proud to be very
beneficial for me.
I learnt quite a lot about Electronic Department ,and Electronic Energy Meters , Hybrid
Micro-electronic Circits and other electronic devices which are used in our daily life.
The project has been completed with great dedication and sincere efforts.
We have some limitations that can be overcome as a measure of further enhancement of the
project and increase its utility.

8. BIBLIOGRAPHY
• "Handbook of Electricity Metering" by The Edison Electric Institute-- The Bible of
electric meters, continuously updated since electricity was invented.
• http://en.wikipedia.org/wiki/Electricity_meter
• www.google.com

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ELECTRONICS AND COMMUNICATION

“PRODUCTION OF ENERGY METER”

( A KAILASH GROUP COMPANY )

From: 24th may to 24th june

Dhram pal Singh Mahendra Agarwal

This is to certify that the report entitled

Date: Mr. Deepak Chaturvedi

I express my deepest sense of gratitude towards Mr. Deepak Chaturvedi, HOD

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

This training report submitted by me is written on the basis of

the practical gained during my training period.

I had completed this report. It’s a great pleaser & satisfaction to

develop energy meter. I lean to tackle different problems that come

while developing any report.

report. But, besides best effect, it may have few shortcomings.

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

4. 3-PHASE WHOLE CURRENT METER……………………………………………..14 - 19

FIG. NO. FIG. NAME PAGE

(i) 3-PHASE STATIC WATT HOUR METER 9

( ii ) 3-PHASE WHOLE CURRENT METER 19

( iii ) CONNECTION DIAGRAM OF 3-PHASE 22

WHOLE CURRENT METER

ELECTRONICS AND COMMUNICATION

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

1.1 APPLICABLE STANDARDS

(d) CBIP 88 Revised: a.c. static watt hour meters

1.2 QUALITY SYSTEM

1.2.2 ISO 9001 Certificate of Registration:

● Design manufacturing & supply of thick film hybrid microcircuits.

1.2.4 ISI Mark:

•What is an Energy Meter?

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

with the energy consumption recorded by a reference meter.

Accuracy(%) = (EMUT - ERef) x 100

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

•What is the effect of installation parameter on energy recording?

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

•Meters accuracy are defined at reference conditions. However, in field voltage,

•Can the accuracy of meter be altered in field?

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

•What is AMR system?

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

2.2 Principle of operation

Block Diagram (i)

Digital signal processor

O/P, CAL Phase

2.3 Display parameters

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

2. 1-Phase Energy Meter Production Process

Put NL and PL terminal in T. Block

Tight screw M4X8 of lower side of NL & PL

Put PS & NS terminals in Jig

Put glue stick between Ph & Nu primary in Power

Tight Shunt, Ph wire, MOV & 10nF in PS with

Tight Nu primary, Nu Wire, MOV & 10nF in NS with

Place the PS and NS terminals assy in Base

Tight M4X8 screws in PS & NS terminals

Put Metal CT in Nu primary & tight in meter base